A pouch for dispensing a substance and a method of using said pouch

ABSTRACT

A pouch for dispensing a substance and a method of using the pouch is disclosed. The pouch is formed from first and second walls of flexible material having mating peripheral edges which form an enclosure. The pouch has a width, a first end which is initially open, a second end, and first and second side seals which extend from the first end to the second end. A frangible seal is spaced apart from the second end. The frangible seal extends across a major portion of the width. The pouch also has a gusset formed between the second end and the frangible seal. The gusset bas a discharge opening formed therein through which a substance, which is retained in the enclosure after the first end is sealed, can be discharged.

FIELD OF THE INVENTION

This disclosure relates to a pouch having a frangible seal for dispensing a substance and a method of using the pouch.

BACKGROUND OF THE INVENTION

Currently, many fast food and local restaurants use squeeze bottles, situated at the dining tables, to dispense various condiments such as: ketchup, mustard, honey, syrup for pancakes, etc. These squeeze bottles are normally refilled and reused multiple times. This presents a health issue in that the 15 employees are required to refill each squeeze bottle from a larger container periodically. The refilling process can be messy and cumbersome. But most important, the refilling process can cause the substance being inserted into the individual squeeze bottles to become contaminated. Contaminated food products can cause serious health issues for the general public and should be avoided at all cost. In addition, many food service workers in restaurant kitchens also utilize squeeze bottles as well as mechanical, sauce dispensing guns to dispense various food substances, especially, mustard, barbeque sauce, etc. when preparing food. Some of these mechanical dispensers utilize a plastic bag filled with the food substance being dispensed. These mechanical dispensers 25 are expensive to purchase. These mechanical dispensers also need to be refilled and cleaned on a regular basis. U.S. Patent Application Publication 2013/0233886, to Long et al., teaches one such dispensing gun.

Today, many household food items are now being sold at the grocery stores in squeeze bottles. It is now common to purchase ketchup, mustard, relish, sour cream, chocolate, mayonnaise, salad dressings, barbeque sauce, and even cheese, in such squeeze bottles. These bottles are not meant to be refilled but they still have certain disadvantages. Bottles, in general, tend to be heavier than flexible pouches and therefore the transportation and delivery cost of such bottles is more expensive. In addition, many such bottles are usually packed in cardboard boxes using cardboard dividers. The cardboard dividers add another cost to the shipping process.

Another disadvantage with squeeze bottles is that the outlet spout is normally covered by some type of flip or screw cap. During repeated use, the food substance being dispensed tends to accumulate at and around the outlet spout and this can present an unpleasant messy sight when the cap is again removed or reopened. This messy zone at the outlet spout is unsightly and can present an unfavorable aesthetic experience to the end user.

A pouch having a frangible seal for dispensing a substance is disclosed that solves the above mentioned problems. A method of using the pouch to dispense a substance is also disclosed.

SUMMARY OF THE INVENTION

Briefly, this disclosure relates to a pouch having first and second walls of flexible material with mating peripheral edges which form an enclosure. The pouch has a width, a first end which is initially open, a closed second end, and first and second side seals, each of which extends from said first end to said second end. The open first end permits the enclosure to be filled with a substance before being sealed. A frangible seal is spaced apart from the second end. The frangible seal extends across a major portion of the width of the pouch. The pouch also includes a gusset formed between the second end and the frangible seal. The gusset has a discharge opening formed therein through which a substance, which is retained in the enclosure after the first end is sealed, can be discharged.

This disclosure also relates to a pouch having first and second walls of flexible material with mating peripheral edges which form an enclosure. The pouch has a width, a first end which is initially open, a sealed second end, and first and second side seals. The open first end permits the enclosure to be filled with a substance before being sealed. A line of weakness is positioned adjacent to the second end and extends across the width of the pouch. The pouch also has a frangible seal spaced apart from the line of weakness which extends across a major portion of the width. The first and second side seals extend between the first end and the second end. The pouch further has a gusset formed between the line of weakness and the frangible seal. The gusset has a discharge opening formed therein which a substance, which is retained in the enclosure after the first end is sealed, can be discharged in a controlled manner.

A method of using the pouch is also disclosed. The pouch has first and second walls of flexible material with mating peripheral edges which form an enclosure. The pouch has a width, a first end which is initially open, a sealed second end, and first and second side seals. The open first end permits the enclosure to be filled with a substance before being sealed. A line of weakness is positioned adjacent to the second end and extends across the width of the pouch. The pouch also has a frangible seal spaced apart from the line of weakness which extends across a major portion of the width. The first and second side seals extend from the first end to the second end. The pouch further has a gusset formed between the line of weakness and the frangible seal. The gusset has a discharge opening formed therein through which a substance, which is retained in the enclosure after the first end is sealed, can be discharged. The method includes breaking the line of weakness and removing the sealed second end from the pouch. An external pressure is then applied to the pouch which is sufficient to break the frangible seal. The method further includes continuing to apply an external pressure to the pouch which causes the substance to be discharged, in a controlled manner, through the discharge opening.

The general object of this disclosure is to provide a pouch having a frangible seal for dispensing a substance. A more specific object of this disclosure is to provide a pouch which utilizes a gusset having a discharge opening formed therein through which a substance can be dispensed.

Another object of this disclosure is to provide a pouch which utilizes a gusset which enables the pouch to stand upright when set on a flat surface such as a counter.

A further object of this disclosure is to provide a pouch which utilizes a gusset, which enables the pouch to stand upright when set on a flat surface, and a line of weakness which enables the second end to be removed before a substance is dispensed from the pouch.

Still another object of this disclosure is to provide a pouch which utilizes a sealed second end to protect the discharge opening.

Still further, an object of this disclosure is to provide a method of using the pouch to dispense a substance.

Other objects and advantages of the present disclosure will become more apparent to those skilled in the art in view of the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a pouch.

FIG. 2 is a side view of the pouch shown in FIG. 1.

FIG. 3 is a side view of the pouch shown in FIG. 2 after it has been filled with a substance.

FIG. 4 is a perspective view of the pouch with the gusset being used to support the pouch in a standup position.

FIG. 5 is a cross-sectional view of an unfilled pouch depicting a strip of thermoplastic material used to form the frangible seal.

FIG. 6 is a cross sectional view of an unfilled pouch wherein the first and second walls are sealed together to form the frangible seal.

FIG. 7 is a bottom view of a gusset showing the discharge opening being initially closed.

FIG. 8 is a bottom view of another embodiment of a gusset showing the discharge opening being initially open.

FIG. 9 is a front view of another embodiment of a pouch having a frangible seal.

FIG. 10 is a side view of the pouch shown in FIG. 9.

FIG. 11 is a side view of the pouch shown in FIGS. 9 and 10 after it has been filled with a substance and the first end has been sealed.

FIG. 12 is a front view of the pouch shown in FIGS. 9 and 10 after the line of weakness has been broken and the second end is removed.

FIG. 13 is a side view of the pouch shown in FIG. 12.

FIG. 14 is a side view of the filled pouch shown in FIG. 11 with the first and second portions of the gusset extending outward.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-6, a pouch 10 is shown constructed of a first wall 12 and a second wall 14. By “pouch” it is meant a small bag or sack which can be used to package a variety of substances or items. The first and second walls, 12 and 14 respectively, can be formed from one or more materials. Desirably, the materials are flexible. By “flexible” it is meant capable of being bent or flexed; pliable. The first and second walls, 12 and 14 respectively, can be formed from the same material or from different materials. Desirably, the first and second walls, 12 and 14 respectively, are formed from the same material. Alternatively, the first and second walls, 12 and 14 respectively, can be formed from a single sheet of material, see FIGS. 5 and 6.

The pouch 10 could also be formed by folding a single sheet of flexible material over itself and sealing an end and one of the first or second sides. Another way to forming the pouch 10 would be to construct a seamless tube that is sealed at one end.

The first and second walls, 12 and 14 respectively, can be formed or constructed from various kinds of flexible materials. For example, the first and second walls, 12 and 14 respectively, can be formed from a plastic material, a thermoplastic material, a composite material, a laminate, paper, film, foil, or a combination of one or more materials known to those skilled in the art. Desirably, the first and second walls, 12 and 14 respectively, are formed from a polymeric material. By “polymeric material” it is meant a product of a polymerization reaction of natural, synthetic, or natural and synthetic ingredients, and is inclusive of homopolymers, copolymers, terpolymers, etc. In general, the layer or layers of a film or substrate may include a single polymer, a mixture of a single polymer and one or more non-polymeric materials, a combination of two or more polymeric materials blended together, or a mixture of a blend of two or more polymeric materials and non-polymeric materials. Desirably, each of the first and second walls, 12 and 14 respectively, is a polymeric film formed from the same material. The interior surface of the first and second walls, 12 and 14 respectively, can be a sealant layer. A sealant layer allows another thermoplastic material to be easily bonded to it.

The first and second walls, 12 and 14 respectively, can vary in size and shape. A rectangular shape is shown in FIG. 1, but any geometrical shape or configuration, including but not limited to: a square, an oval, a circle, a triangle, or an irregular shape could be utilized. The first and second walls, 12 and 14 respectively, can be formed from a heat sealable plastic film of either single ply or multi-ply construction. In addition, the plastic film can be laminated to other materials, such as paper, foil, etc. If the first and second walls, 12 and 14 respectively, are formed from a flexible material that consists of more than one layer, then it is desirable that the inner layer be a heat sealable thermoplastic.

Referring to FIG. 2, the first wall 12 has a thickness t₁ and the second wall 14 has a thickness t₂. The thicknesses t₁ and t₂ can vary. Generally, the thickness t₁ of the first wall 12 is equal to or approximately equal to the thickness t₂ of the second wall 14. The thicknesses t₁ and t₂ of the first and second walls, 12 and 14 respectively, can range from between about 0.1 millimeters to about 10 millimeters. Desirably, each of the thicknesses t₁ and t₂ is less than about 8 millimeters. More desirably, each of the thicknesses t₁ and t₂ is less than about 5 millimeters. Even more desirably, each of the thicknesses t₁ and t₂ is less than about 3 millimeters. Most desirably, each of the thicknesses t₁ and t₂ is less than about 2 millimeters.

Referring again to FIGS. 1-6, the first and second walls, 12 and 14 respectively, have mating peripheral edges 16, 16 which form an enclosure 18, see FIGS. 5 and 6. Desirably, the peripheral edges 16, 16 of the first and second walls, 12 and 14 respectively, are coterminuous. By “coterminuous” it is meant sharing a boundary; contiguous; contained in the same boundaries.

Referring again to FIGS. 1 and 2, the pouch 10 has a longitudinal central axis X-X, a vertical central axis Y-Y, and a transverse central axis Z-Z. The pouch 10 also has a length l, a width w and a thickness t. The length l, the width w, and the thickness t can all vary in dimension. In addition, the thickness t can vary along the length l, if desired.

The pouch 10 can be constructed to house or retain any kind of substance, item(s) or article(s) 28. The pouch 10 is particularly useful in housing or retaining a food substance, such as a condiment, like ketchup or mustard. When the pouch 10 is constructed to house a food substance, it can vary in dimensions. However, a pouch 10 having a length l of between about 25 cm to about 30 cm, a width w of between about 10 cm to about 12.5 cm, and a thickness t, before being filled with a substance 28, of between about 1-5 millimeters, works well.

It should be understood that the pouch 10 can be made smaller or larger in size, depending on the substance it will house and the use for which it is intended.

Referring again to FIGS. 1-5, the pouch 10 has a first end 20, a second end 22, a first side 24 and a second side 26. The first end 20 is initially open so that a substance 28 can be inserted into the enclosure 18. After the enclosure 18 is filled with a substance 28, the first end 20 can be closed by a seal 30, see FIGS. 3 and 4. The second end 22 is closed. The second end 22 could be closed by forming the first and second walls, 12 and 14 respectively, from a single sheet of material, as shown in FIG. 5. Alternatively, the second end 22 could be formed from a separate piece of material which is secured to the first and second walls, 12 and 14 respectively, or it could be sealed. The pouch 10 also has a first side seal 34 and a second side seal 36. Each of the seals 30, 34 and 36 can be vary in type, shape, dimension, etc. The seals 30, 34 and 36 can be hermetic seals. The seals 30, 34 and 36 are not designed to be broken. The seals 30, 34 and 36 can be any kind or type of seal known to those skilled in the art. In addition, the seals 30, 34 and 36 and can be formed by any known methods. For example, the seals 30, 34 and 36 could be a heat seal, a pressure seal, a heat and pressure seal, an adhesive seal, a thermal bond, an ultrasonic seal, etc. All of the seals 30, 34 and 36 do not have to be the same, and one or more of the seals 30, 34 and 36 could be formed a different way.

Referring now to FIG. 4, it should be understood that the seals 30, 34 and 36 can vary in height or width, depending upon their orientation to the longitudinal central axis X-X. For example, the seal 30 has a height h, measured parallel to the longitudinal central axis X-X, which ranges from between about 0.25 centimeters (cm) to about 2.54 cm. Desirably, the height h of the seal 30 can range from between about 0.38 cm to about 1.25 cm. More desirably, the height h of the seal 30 can range from between about 0.38 cm to about 0.75 cm. Most desirably, the height h of the seal 30 is about 0.64 cm. The first and second side seals, 34 and 36 respectively, would have a width, measured parallel to the longitudinal central axis X-X, which would correspond in dimension to the height h of the seal 30.

Referring to FIG. 3, the substance 28 that can be housed or retained in the enclosure 18 of the pouch 10 can vary in composition and viscosity. By “composition” it is meant the combining of distinct parts or elements to form a whole; the manner in which such parts are combined or related. By “viscosity” it is meant the condition or property of being viscous; a numerical measure of the degree to which a fluid resists flow under an applied force.

The substance 28 can be a food item or a non-food item. Examples of a food item include but are not limited to: ketchup, mustard, relish, a sauce, for example barbeque sauce or hot sauce, a salad dressing, icing for a cake, cream, sour cream, a syrup such as corn syrup, chocolate, mayonnaise, cheese, peanut butter, jam, jelly, honey, etc. Examples of a non-food item include but are not limited to: grease, motor oil, a lubricant, putty, caulking, cement, a glue, paste, etc. Almost any item, article or thing that is not a liquid could be housed or retained in the pouch 10.

The viscosities of some common food and non-food items are shown in Table 1 below.

TABLE 1 Approximate Viscosities of Common Materials (At Room Temperature - 21° C. (70° F.)) Viscosity in Material Centipoise Water 1 cps Milk 3 cps SAE 10 Motor Oil 85-140 cps SAE 20 Motor Oil 140-420 cps SAE 30 Motor Oil 420-650 cps SAE 40 Motor Oil 650-900 cps Castrol Oil 1000 cps Corn Syrup 5,000 cps Honey 10,000 cps Chocolate 25,000 cps Ketchup 50,000 cps Mustard 70,000 cps Sour Cream 100,000 cps Peanut Butter 250,000 cps Note: The data in table 1 was obtained from V&P Scientific, Inc.

Referring now to FIGS. 5 and 6, the pouch 10 also has a frangible seal 38 spaced apart from the second end 22. The frangible seal 38 can extend from the inside surface of the first wall 12 to the inside surface of the second wall 14, as is shown in FIG. 5. Alternatively, the frangible seal 38 can extend across a major portion of the width w of the pouch 10. Desirably, the frangible seal 38 extends completely across the width w of the pouch 10. For example, the frangible seal 38 could extend from the first side 24 to the second side 26. The frangible seal 38 hermetically seals the enclosure 18 when it extends across at least the distance between the inside surfaces of the first and second walls, 12 and 14 respectively. By “hermetic” it is meant completely sealed, especially against the escape or entry of air, impervious to outside interference or influence.

The frangible seal 38 can be formed using heat, pressure, heat and pressure, using an adhesive, forming a thermal bond, forming an ultrasonic seal, or in other ways known to those skilled in the art. Desirably, the frangible seal 38 is formed using heat and pressure.

The frangible seal 38 can be positioned at any desired distance from the second end 22. The exact distance can vary depending on the overall size of the pouch 10. For a pouch 10 having a length l of from between about 25 centimeters to about 31 centimeters, and a width of from between about 10 centimeters to about 13 centimeters, the frangible seal 38 could be positioned within about 5 centimeters of the second end 22. Desirably, for this size pouch 10, the frangible seal 38 is positioned within about 4 centimeters of the second end 22. More desirably, for this size pouch 10, the frangible seal 38 is positioned within about 3 centimeters of the second end 22. Even more desirably, for this size pouch 10, the frangible seal 38 is positioned within about 2 centimeters of the second end 22. Most desirably, for this size pouch 10, the frangible seal 38 is positioned within about 1.5 centimeters of the second end 22.

The frangible seal 38 is constructed such that it will break or rupture at a predetermined force or pressure. As the pouch 10 is externally squeezed, an equivalent internal pressure or force is created within the enclosure 18 and this pressure or force will be exerted upon the frangible seal 38. The amount of pressure or force needed to break or rupture the frangible seal 38 can vary depending on the size of the pouch 10, the materials from which the first and second walls, 12 and 14 respectively, are constructed, how the frangible seal 38 is constructed, the dimensions of the frangible seal 38, etc. Desirably, the amount of pressure or force needed to break or rupture the frangible seal 38 is at least about 800 grams force/centimeter (gf/cm). More desirably, the amount of pressure or force needed to break or rupture the frangible seal 38 is at least about 850 gf/cm. Even more desirably, the amount of pressure or force needed to break or rupture the frangible seal 38 ranges from between about 800 gf/cm to about 1,500 gf/cm. Most desirably, the amount of pressure or force needed to break the frangible seal 38 ranges from between about 900 gf/cm to about 1,200 gf/cm.

Table 2 below lists the test data obtained from testing 15 sample pouches according to ASTM F904. In the ASTM F904 test, one variation was made. Instead of using a 149° C. (300° F.) seal bar, an impulse sealer was used.

TABLE 2 Peak Peak Avg. Avg. Initial Initial Seal Seal Seal Seal Peak Peak Strength Strength Strength Strength Sample [gf/in] [gf/cm] [gf/in] [gf/cm] [gf/in] [gf/cm] 1 2394 942.52 2394 942.52 891 350.79 2 2456 966.93 2555 1005.91 2465 970.47 3 2488 979.53 2529 995.67 2472 973.23 4 2429 956.30 2496 982.68 2425 954.72 5 2479 975.98 2611 1027.95 2524 993.70 6 2507 987.01 2611 1027.95 2528 995.28 7 2395 942.91 2395 942.91 2015 793.31 8 2480 976.38 2517 990.94 2453 965.75 9 2366 931.50 2445 962.60 2370 933.07 10 2281 898.03 2281 898.03 1939 763.39 11 2419 952.36 2419 952.36 2042 803.94 12 2420 952.76 2479 975.98 2413 950.00 13 2485 978.35 2607 1026.38 2510 988.19 14 2761 1087.01 3014 1186.61 2839 1117.72 15 2605 1025.59 2758 1085.83 2643 1040.55 Mean 2464 970.08 2541 1000.39 2302 906.30 Standard 110.11 43.31 174.64 68.71 457.42 180.15 deviation Note: In Table 2, the values stated in gf/inch are divided by 2.54 cm/inch to obtain gf/cm.

The Peak Seal Strength in Table 2 ranges from between 898.03 gf/cm to 1,085.83 gf/cm. This establishes the present range of from between about 800 gf/cm to about 1,500 gf/cm.

Referring again to FIG. 5, one way of forming the frangible seal 38 is to position a strip of thermoplastic material 40, such as a thermoplastic film, across the width w of the pouch 10 or across a major portion of the width w of the pouch 10. For example, the thermoplastic material 40 can be positioned between the inside surfaces of the first and second walls, 12 and 14 respectively. Alternatively, the strip of thermoplastic material 40 can extend into the first and second side seals, 34 and 36 respectively. Yet another way is to size the strip of thermoplastic material 40 so that it extends over the entire width w of the pouch 10, between the first side 24 and the second side 26.

The strip of thermoplastic material 40 is heat sealable and can be bonded to the inside sealant surfaces of the first and second walls, 12 and 14 respectively. The strip of thermoplastic material 40 can be constructed such that it will break or rupture at a predetermined pressure or force. One way of doing this is to include a contaminant that allows the strip of thermoplastic material 40 to break at a predetermined pressure or force. Other ways of constructing the strip of thermoplastic material 40 such that it will break or rupture at a predetermined pressure or force are well known to those skilled in the art.

Referring now to FIG. 6, another way of forming the frangible seal 38 is to seal the inside surfaces of the first and second walls, 12 and 14 respectively, to each other. In this case, the inside surfaces of the first and second walls, 12 and 14 respectively, must be sealant layers. By “sealant layers” it is meant that the two layers can be sealed or joined together using heat, pressure, or heat and pressure. The sealant layers will allow the frangible seal 38 to be break, rupture or peel apart when a predetermined pressure or force is applied against it. One way of assuring that the frangible seal 38 will break, rupture or peel apart at a predetermined pressure or force is to include a contaminant in one or both of the sealant layers. The contaminant will allow the frangible seal 38 to break, rupture or peel apart when a predetermined pressure or force is applied to it.

Referring again to FIGS. 1 and 2, the frangible seal 38 is depicted as a continuous line having a height h₁. The frangible seal 38 can be a linear line or a non-linear line. Desirably, the frangible seal 38 is a linear line. The height h₁ of the frangible seal 38 can vary. Desirably, the height h₁ of the frangible seal 38 is at least about 0.25 centimeters (cm). More desirably, the height h₁ of the frangible seal 38 ranges from about 0.25 cm to about 0.5 cm. Even more desirably, the height h₁ of the frangible seal 38 is at least about 0.4 cm. Most desirably, the height h₁ of the frangible seal 38 is at least about 0.3 cm.

Referring now to FIGS. 1 and 5, the strip of thermoplastic material 40 has a height h₂, see FIG. 5. The height h₂ of the strip of thermoplastic material 40 can be less than, equal to, or be greater than the height h₁ of the frangible seal 38. Desirably, the height h₂ of the strip of thermoplastic material 40 is equal to the height h₁ of the frangible seal 38.

Referring again to FIGS. 1-6, the pouch 10 further includes a gusset 42. By “gusset” it is meant a folded insert that allows a package or pouch to expand outward. The gusset 42 is formed between the second end 22 and the frangible seal 38. The gusset 42 can be formed from a single sheet material that is used to form the first and second walls, 12 and 14 respectively, see FIGS. 5 and 6. Alternatively, the gusset 42 can be a separate piece of material that is secured or attached to the first and second walls, 12 and 14 respectively. In any case, the gusset 42 forms a closed second end 22 of the pouch 10 as is known to one skilled in the art. As such, it should be understood that when the first and second side seals, 34 and 36 respectively, are formed between the first end 20 and the second end 22, that in the region of the gusset 42, the first and second walls, 12 and 14 respectively, may be bonded to: 1) each other, 2) the gusset 42, or 3) the gusset 42 and each other. As indicated in FIGS. 4-6, the gusset 42 is an integral part of the first and second walls, 12 and 14 respectively.

The gusset 42 includes a first portion 44 and a second portion 46. The first and second portions, 44 and 46 respectively, are folded to form an inverted V shape. The first and second portions, 44 and 46 respectively, of the gusset 42 can move or extend outwardly to enable the pouch 10 to stand upright. The first portion 44 and the second portion 46 are normally of the same size and configuration.

Referring again to FIGS. 3-8, as the first and second portions, 44 and 46 respectively, of the gusset 42 move or extend outward, the gusset 42 can take on a more flat or unfolded configuration. For example, as shown in FIG. 3, the pouch 10 filled with substance 28, is shown with frangible seal 38 ruptured and the gusset 42 unfolded such that the pouch 10 can stand in an upright position. FIG. 4 shows the pouch 10 in a configuration where the gusset 42 is unfolded. In FIGS. 7 and 8, the gusset 42 is depicted as having a rectangular shape with a vertical central axis Y₁-Y₁ and a transverse central axis Z₁-Z₁. The first portion 44 has a width w₁ and the second portion 46 has a width w₂. The width w₁ can be less than, equal to or larger than the width w₂. Desirably, the width w₁ will be equal to the width w₂. The widths w₁ and w₂ can vary in dimension depending on the overall size of the pouch 10. For a pouch 10 having length l of about 25 cm and a width w of about 10 cm, each of the widths w₁ and w₂ of the first and second portions, 44 and 46 respectively, can range from between about 1.25 cm to about 7.5 cm. More desirably, for this size pouch 10, each of the widths w, and w₂ of the first and second portions, 44 and 46 respectively, can range from between about 1.25 cm to about 5 cm. Even more desirably, for this size pouch 10, each of the widths w₁ and w₂ of the first and second portions, 44 and 46 respectively, can range from between about 1.25 cm to about 2.5 cm. Most desirably, for this size pouch 10, each of the widths w₁ and w₂ of the first and second portions, 44 and 46 respectively, can range from between about 1.5 cm to about 2.5 cm.

Still referring to FIGS. 5-8, the gusset 42 has a discharge opening 48 or 48′ formed therein. The discharge opening 48 or 48′ is formed in the gusset 42 and provides a way through which the substance 28, which is retained in the enclosure 18 of the pouch 10, can be discharged. The discharge opening 48 or 48′ allows the substance 28 to be dispensed in a controlled manner when an external pressure is applied to the pouch 10. The discharge openings 48 or 48′ can vary in size, shape and location. In FIG. 5, the discharge opening 48 is aligned along the longitudinal central axis X-X while in FIG. 6, the discharge opening 48 is offset from the longitudinal central axis X-X.

The discharge opening 48 has an initially closed configuration while the discharge opening 48′ has an initially open configuration. Either form of discharge opening 48 or 48′ can be used. When the discharge opening 48, with its initially closed configuration is utilized, it will remain closed until it is broken and acquires an open configuration. Once the discharge opening 48 is opened, it will remain open. The discharge opening 48′ is initially open and will remain open.

Referring to FIG. 7, the discharge openings 48 is depicted as being formed along the vertical central axis Y₁-Y₁ of the gusset 42. In fact, the discharge opening 48 is formed at the intersection of the vertical central axis Y₁-Y₁ and the transverse central axis Z₁-Z₁. Alternatively, the discharge opening 48 could be offset from the vertical central axis Y₁-Y₁ of the gusset 42. Likewise, the discharge opening 48 could be offset from the transverse central axis Z₁-Z₁ of the gusset 42 as well. Desirably, the discharge opening 48 is aligned along the vertical central axis Y₁-Y₁ of the gusset 42. The discharge opening 48, with its initially closed configuration, can be formed in a variety of ways. For example, the discharge opening 48 can consist of one or more score lines, or a thinned area. The discharge opening 48 can also include two or more intersecting score lines or partially cut lines. As such, the discharge opening 48 can be broken or opened at a later time by exerting a pressure or force against it. The pressure needed to break or open the discharge opening 48, with its initially closed configuration, can be less than, equal to, or be greater than the pressure or force needed to break or rupture the frangible seal 38. Desirably, the pressure or force needed to break or open the discharge opening 48 is less than or equal to the pressure or force needed to break or rupture the frangible seal 38. More desirably, the pressure or force needed to break or open the discharge opening 48 is equal to the pressure or force needed to break or rupture the frangible seal 38. This means that the pressure or force needed to break or open the discharge opening 48, with its initially closed configuration, is less than about 1,500 gf/cm. Desirably, the pressure or force needed to break or open the discharge opening 48, with its initially closed configuration, can range from between about 800 gf/cm to about 1,200 gf/cm. Most desirably, the pressure or force needed to break or open the discharge opening 48, with its initially closed configuration, can range from between about 850 gf/cm to about 1,200 gf/cm.

Still referring to FIG. 7, the discharge opening 48 is depicted as an X shaped opening created by two intersecting lines. In addition, two additional smaller lines intersect each of the original two intersecting lines at spaced intervals. Various other arrangements for the discharge opening 48 are also possible.

The formation of the discharge opening 48, with its initially closed configuration, can be obtained a variety of ways known to those skilled in the art. For example, the discharge opening, with its initially closed configuration, can be made or constructed by scoring, partially cutting or thinning the material that forms the gusset 42. Scores can be made using laser scoring, die scoring, ultrasonic scoring, etc. With a laser score, some of the material is thermally melted away. With a die score, some of the material is cut away.

Partial cuttings, where the cut does not extend completely through the thickness of the material forming the gusset 42, can be made using various kinds of cutting blades, including but not limited to: reciprocating blades, circular blades, knives, saws, a band saw, a circular saw, using water jet technology, using ultrasonics, etc.

Thinning of the material forming the gusset 42 can be accomplished by partially punching the material, stretching the material, pressing the material, removing a portion of the material, or by some other means known to those skilled in the art.

The discharge opening 48, with its initially closed configuration, could be a single slit; a V shaped slit; an X shaped slit created by two intersecting slits; an X shaped slit created by two intersecting slits with the addition of additional slits spaced along each leg of the X shaped slits; etc. The discharge opening 48, with its initially closed configuration, can be opened after the frangible seal 38 is broken or ruptured and the substance 28 presses against the scored or thinned shaped slits which define the discharge opening 48. This pressure will be sufficient to break or open the discharge opening 48. After the discharge opening 48, with its initially closed configuration, is opened, its unique size and shape will cooperate with the viscosity of the substance 28 and limit leakage of the substance 28 from the enclosure 18 of the pouch 10.

Referring now to FIG. 8, the discharge opening 48′, with its initially open configuration, is shown. The discharge opening 48′ is depicted as being formed along the vertical central axis Y₂-Y₂ of the gusset 42. In fact, the discharge opening 48′ is formed at the intersection of the vertical central axis Y₁-Y₁ and the transverse central axis Z₁-Z₁. Alternatively, the discharge opening 48′ could be offset from the vertical central axis Y₁-Y₁ of the gusset 42. Likewise, the discharge opening 48′ could be offset from the transverse central axis Z₁-Z₁ of the gusset 42 as well. Desirably, the discharge opening 48′ is aligned along the vertical central axis Y₁-Y₁ of the gusset 42. The discharge opening 48′, with its initially open configuration, can be formed in a variety of ways. For example, the discharge opening 48′ can be a through aperture that is drilled, cut, punched, die cut, etc. through the thickness of the material forming the gusset 42. The discharge opening 48′ is relatively small in size or diameter. When the discharge opening 48′ is a circle, its diameter is usually less than about 0.5 cm. Desirably, the discharge opening 48′ has a diameter of less than about 0.38 cm. More desirably, the discharge opening 48′ has a diameter of less than about 0.25 cm. Even more desirably, the discharge opening 48′ has a diameter of less than about 0.2 cm. Most desirably, the discharge opening 48′ has a diameter of less than about 0.13 cm.

The discharge opening 48′, with its initially open configuration, can be formed into almost any known geometrical shape. The discharge opening 48′ could be shaped as a circle, as is shown in FIG. 8. In addition, the discharge opening 48′ could be shaped as: an oval, a square, a rectangle, a triangle, etc. The discharge opening 48′, with its initially open configuration, will also experience limited, if any, leakage because the diameter or the size of the discharge opening 48′ is very small. This means that except when an external pressure is applied to the pouch 10 by squeezing it, essentially no leakage of the substance 28 in the enclosure 18 will occur from the discharge opening 48′.

It is desirable to keep the gusset 42 and the discharge opening 48 or 48′ clean and free of contaminants. For example, the gusset 42 and the discharge opening 48 or 48′ may be kept clean and free of contaminants by placing a label (not shown) on at least a portion of the gusset 42. Desirably, the label will cover the portion of the gusset 42 that includes the discharge opening 48 or 48′.

Referring now to FIGS. 9-14, another embodiment of a pouch 10′ is depicted. The pouch 10′ is similar to the pouch 10 in many respects and similar numbers will be used to denote common structure. The pouch 10′ has a first wall 12 and a second wall 14. The first and second walls, 12 and 14 respectively, can be formed from a flexible material having mating peripheral edges 16 which form an enclosure 18. The pouch 10′ has a length l₁, a width w, and a thickness t. The pouch 10′ has a first end 20, which is initially open, a second end 22, and first and second sides, 24 and 26 respectively. The open first end 20 permits the enclosure 18 to be filled with a substance 28 before being closed by a seal 30. The second end 22 can be sealed by a seal 32 and the first and second sides, 24 and 26 respectively, are closed by first and second side seals, 54 and 56 respectively.

The pouch 10′ differs from the pouch 10 in that it has a line of weakness 50 positioned adjacent to the second end 22. The line of weakness 50 extends across the width w of the pouch 10′. The line of weakness 50 can be formed a variety of ways known to those skilled in the art. For example, the line of weakness 50 can be a score line, a perforated line, a cut line that extends partially through the thickness of the material which forms the pouch 10′, etc. The line of weakness 50 can be a linear line or a non-linear line. Desirably, the line of weakness 50 is a linear line. The line of weakness 50 can be aligned parallel to the second end 22 or be aligned at an angle to the second end 22. Desirably, the line of weakness 50 is aligned parallel to the second end 22.

The line of weakness 50 is depicted in FIG. 9 as being a perforated line. By “perforations” it is meant a hole or series of holes punched or bored through something, especially a hole in a series, separating sections in a sheet or roll. The line of weakness 50 can consist of a plurality of holes separated by land areas. The size and shape of the holes can vary, as can the width of the land areas.

It should be understood that this disclosure is not limited to constructing the line of weakness 50 as a perforated line.

The line of weakness 50 can be located from between about 0.25 cm to about 2.5 cm inward from the second end 22. Desirably, the line of weakness 50 is located at least about 0.64 cm inward from the second end 22. More desirably, the line of weakness 50 is located within about 2 cm from the second end 22. Even more desirably, the line of weakness 50 is located at least about 1.5 cm from the second end 22. Most desirably, the line of weakness 50 is located from between about 0.5 cm to about 1.25 cm from the second end 22.

When the line of weakness 50 is broken, the sealed second end 22 can be physically removed from the pouch 10′. The sealed second end 22 functions to keep the discharge opening 48 or 48′ clean and free of contaminants.

Referring again to FIGS. 9-14, the pouch 10′ also contains a frangible seal 38 spaced apart from the line of weakness 50. The frangible seal 38 extends across a major portion of the width w of the pouch 10′. Desirably, the frangible seal 38 extends across the entire width w of the pouch 10′.

Referring again to FIG. 9, the pouch 10′ can include an optional notch 52 formed at one end of the line of weakness 50. The notch 52 can vary in shape and size. The notch 52 can have any geometrical shape. The notch 52 is depicted as a V-shaped notch. The notch 52 functions to assist one in starting to break the line of weakness 50. Alternatively, a pair of notches 52, 52 could be utilized, with each notch 52 located at an opposite end of the line of weakness 50. When two notches 52, 52 are present, the line of weakness 50 could be easily broken starting at either end.

It should be understood that the notch 52 or notches 52, 52 are optional. The line of weakness 50 can be broken without the presence of the notch 52; it may simply take a little extra force in starting to break the line of weakness 50.

Still referring to FIGS. 9-14, the pouch 10′ further includes a gusset 42′ formed between the line of weakness 50 and the frangible seal 38. The gusset 42′ has a first portion 44, a second portion 46, and a discharge opening 48 or 48′, see FIG. 14, formed therein through which a substance 28, which is retained in the enclosure 18, can be discharged. The gusset 42′ is open, or unbonded, along each of the first and second sides, 24 and 26 respectively, in the illustrated embodiment. It should be understood that in another embodiment, the gusset 42′ can be bonded along each of the first and second sides, 24 and 26 respectively.

Referring again to FIGS. 12-14, one can clearly see that when the line of weakness 50 is broken or opened, the sealed second end 22 can be completely removed from the pouch 10′. With the second end 22 removed, the first and second portions, 44 and 46 respectively, of the gusset 42′ can unfold or extend outward to establish a pair of feet to enable the pouch 10′ to stand upright.

It should be understood that the seal 32 at the second end 22 may be a hermetic and or a permanent seal. The second end 22 may also be sealed with a peelable heat seal or a label. A peelable heat seal may be used on the gusset 42 such that the first portion and the second portions, 44 and 46 respectively, are peelably heat sealed to each other along at least a portion of the width w of the pouch 10′. Alternatively, a label may be placed on the second end 22 along at least a portion of the width w of the pouch 10′ such that the label adheres to the outside of first and second walls, 12 and 14 respectively. Label stock and peelable heat seals may be used to seal the second end 22 as is known by one skilled in the art.

An external pressure or force can be applied to the pouch 10′ which creates a corresponding equal pressure or force inside the enclosure 18. This pressure or force will cause the frangible seal 38 to break or rupture. This pressure or force will also cause the discharge opening 48, which is initially closed, to open. At this time, the substance 28, retained in the enclosure 18 of the pouch 10′, can be discharged. If the pouch 10′ has a discharge opening 48′, which is initially open, then there is no need to break any portion of it before the substance 28 can be dispensed there through. The substance 28 can be discharged, in a controlled manner, through the discharge opening 48 or 48′.

Method

A method of using the pouch 10 is taught. The method includes forming a pouch 10 having first and second walls, 12 and 14 respectively, made of flexible material and having mating peripheral edges 16, 16 which form an enclosure 18. The pouch 10 has a width w, a first end 20, which is initially open, a second end 22, and first and second sides, 24 and 26 respectively. The open first end 20 allows the enclosure 18 to be filled with a substance 28 before it is closed by a seal 30. The pouch 10 also has a frangible seal 38 spaced apart from the second end 22. The frangible seal 38 extends across at least a major portion of the width w of the pouch 10. The first and second sides, 24 and 26 respectively, are closed by first and second side seals, 34 and 36 respectively, which extend from the first end 20 to the second end 22. The pouch 10 also has a gusset 42 formed between the second end 22 and the frangible seal 38. The gusset 42 has a discharge opening 48 or 48′ formed therein through which a substance 28, which is retained in the enclosure 18, can be discharged. The method includes the steps of applying an external pressure or force to the pouch 10. The pressure or force is sufficient to break the frangible seal 38. The pressure or force is continued to be applied to the pouch 10 which causes discharge opening 48, which is initially closed, to break and open. The substance 28 can then be dispensed, in a controlled manner, through the discharge opening 48.

If the pouch 10 has a discharge opening 48′, which is initially open, then it does not need to be broken or opened. In this situation, the continuous applied pressure or force will dispense the substance 28, in a controlled manner, through the discharge opening 48′.

A method of using the pouch 10′ is also taught. The method includes forming a pouch 10′ having first and second walls, 12 and 14 respectively, made of flexible material and having mating peripheral edges 16, 16 which form an enclosure 18. The pouch 10′ has a width w, a first end 20, which is initially open, a sealed second end 22, and first and second sides, 24 and 26 respectively. The open first end 20 allows the enclosure 18 to be filled with a substance 28 before it is closed by a seal 30. The pouch 10′ also has a line of weakness 50 positioned adjacent to the second end 22. The line of weakness 50 extends across the width w of the pouch 10′. The pouch 10′ also has a frangible seal 38 spaced apart from the line of weakness 50. The frangible seal 38 extends across at least a major portion of the width w of the pouch 10′. The first and second sides, 24 and 26 respectively, are closed by first and second side seals, 54 and 56 respectively. The first and second side seals, 54 and 56 respectively, extend from the first end 20 to the second end 22. The pouch 10′ further includes a gusset 42′ formed between the line of weakness 50 and the frangible seal 38. The gusset 42′ has a discharge opening 48 or 48′ formed therein through which a substance 28, which is retained in the enclosure 18, can be dispensed. This method includes the steps of breaking the line of weakness 50 and removing the sealed second end 22 from the pouch 10′. An external pressure is then applied to the pouch 10′. The external pressure is sufficient to break the frangible seal 38. The pressure or force is continued to be applied to the pouch 10′ which causes discharge opening 48, which is initially closed, to break and open. The substance 28 can then be dispensed, in a controlled manner, through the discharge opening 48.

If the pouch 10′ has a discharge opening 48′, which is initially open, then it does not need to be broken or opened. In this situation, the continuous applied pressure or force will dispense the substance 28, in a controlled manner, through the discharge opening 48′.

It should be understood that removing the external pressure that is being applied to the pouch 10′ will prevent the substance 28, remaining in the pouch 10′, from being dispensed through the discharge opening 48 or 48′. The external force needed to be applied to the pouch 10 or 10′, in order to break the frangible seal 50, is at least about 800 gram force/centimeter.

While the invention has been described in conjunction with a number of specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims. 

1. A pouch comprising: a) first and second walls of flexible material having mating peripheral edges which form an enclosure, said pouch having a width, a first end which is initially open, a closed second end, and first and second side seals which extend from said first end to said second end; b) a frangible seal spaced apart from said second end, said frangible seal extending across a major portion of said width; and c) a gusset formed between said second end and said frangible seal, said gusset having a discharge opening formed therein through which a substance, which is retained in said enclosure after said first end is sealed, can be discharged.
 2. The pouch of claim 1 wherein said first end is hermetically sealed after a substance has been inserted into said enclosure.
 3. The pouch of claim 1 wherein said frangible seal includes a strip of thermoplastic material positioned across a major portion of said width.
 4. The pouch of claim 1 wherein said frangible seal extends across said width.
 5. The pouch of claim 4 wherein said frangible seal has a height of at least about 0.25 centimeters.
 6. The pouch of claim 1 wherein said substance, which is retained in said enclosure, can be dispensed in a controlled manner through said discharge opening when an external pressure is applied to said pouch, and said external pressure is sufficient to break said frangible seal.
 7. The pouch of claim 6 wherein said frangible seal can be broken by a force of at least about 800 grams force/centimeter.
 8. The pouch of claim 1 wherein said pouch has a longitudinal central axis and said discharge opening is aligned along said longitudinal central axis.
 9. The pouch of claim 1 wherein said pouch has a longitudinal central axis and said discharge opening is offset from said longitudinal central axis.
 10. The pouch of claim 1 wherein said second end is sealed.
 11. A pouch comprising: a) first and second walls of flexible material having mating peripheral edges which form an enclosure, said pouch having a width, a first end which is initially open, a sealed second end, and first and second side seals, said open first end permitting said enclosure to be filled with a substance before being sealed; b) a line of weakness positioned adjacent to said second end which extends across said width; c) a frangible seal spaced apart from said line of weakness which extends across a major portion of said width, and said first and second side seals extend between said first end and said second end; and d) a gusset formed between said line of weakness and said frangible seal, said gusset having a discharge opening formed therein through which a substance, which is retained in said enclosure after said first end is sealed, can be discharged.
 12. The pouch of claim 11 wherein said discharge opening is initially closed and can be opened when an external pressure is applied to said pouch, and said external pressure is sufficient to break said frangible seal.
 13. The pouch of claim 11 wherein said discharge opening includes a score line which can be formed with a laser.
 14. The pouch of claim 11 wherein said frangible seal includes a strip of thermoplastic material positioned across a major portion of said width.
 15. The pouch of claim 11 wherein said pouch has a longitudinal central axis and said discharge opening is aligned along said longitudinal central axis.
 16. The pouch of claim 11 wherein said frangible seal can be broken by a force of from between about 800 to about 1,500 gram force/centimeter.
 17. A method of using a pouch formed from first and second walls of flexible material having mating peripheral edges which form an enclosure, said pouch having a width, a first end which is initially open, a sealed second end, and first and second side seals, said open first end allowing said enclosure to be filled with a substance before being sealed; a line of weakness positioned adjacent to said second end which extends across said width; a frangible seal spaced between said first end and said line of weakness which extends across at least a major portion of said width; said first and second side seals extend from said first end to said the second end; and a gusset formed between said line of weakness and said frangible seal, said gusset having a discharge opening formed therein through which a substance, which is retained in said enclosure after said first end is sealed, can be discharged, said method comprising the steps of: a) breaking said line of weakness and removing said sealed second end from said pouch; b) applying an external pressure to said pouch sufficient to break said frangible seal; and c) continuing to apply an external pressure to said pouch which causes said substance to be dispensed, in a controlled manner, through said discharge opening.
 18. The method of claim 17 further comprising an initially closed discharge opening which can be opened by said external pressure applied to said pouch.
 19. The method of claim 17 further comprising an initially open discharge opening through which said substance in said enclosure can be dispensed.
 20. The method of claim 17 wherein said external force needed to be applied to said pouch in order to break said frangible seal is at least about 800 gram force/centimeter. 